Volumized yarn of large denier



Nov. 12, 1968 R. F. DYER 3,410,076

VOLUMIZED YARN OF LARGE DENIER Filed July 30, 1958 5// I EXCESS/CORE RA r/o ARCHzfH/IPED Loci .FIig 6 .5// EXCESS/CORE RATIO Q m 7 2.5// EXCESS/CORE RATIO R lchardFDyer 7. INVENTOR. EXCESS com: RAT/o BY {oz/M M? /l foun ATTORNE 1'8 United States Patent 3,410,076 VOLUMIZED YARN 0F LARGE DENIER Richard F. Dyer, Kingsport, Tenn., assignor to Eastman Kodak Company, Rochester, N.Y., a corporation of New Jersey Continuation-impart of application Ser. No. 544,886,

Nov. 4, 1955. This application July 30, 1958, Ser.

16 Claims. (Cl. 57-140) This application is a continuation-in-part of my copending application Ser. No. 544,886, filed Nov. 4, 1955.

This invention relates to a novel yarn product. More particularly, this invention concerns new bulked yarn products of relatively large deniers.

There are a number of instances in the textile trade such as for drapery and upholstery fabrics where a rough textured yarn of bulky, voluminous nature and of a large denier is desired for use. However, prior to the present invention, such type of yarn material has not been readily and economically obtainable but has required the use of expensive and complicated novelty yarn twisters.

It has been proposed in the art to produce a bulked yarn by blowing multifilament yarn with air. However, for production purposes such prior art procedures on yarn usually has permitted an increase of not more than about 30% in denier due to the contraction of such yarn in the blowing or bulking procedures. Furthermore, in the prior art type of treatment of such yarn, usually it has been required that twist be inserted in the yarn either before or after the bulking or volumizing operation to insure good performance of the yarn in subsequent processing into fabrics.

It is, therefore, believed apparent that the development of a new large denier bulked yarn suitable for drapery and upholstery fabrics and the like represents a highly desirable result.

This invention has for an object to provide a continuous filament yarn having an increase of denier substantially greater and a configuration different than has been obtainable heretofore. Still another object is to provide a yarn made up of heavy denier filaments incorporated into yarns having a texture similar to spun staple fiber yarn. Still a further object is to provide a new voluminous or bulky yarn which may be free of or have low twist. A particular object is to provide new and novel voluminous yarn products from continuous filament yarn, which new products have size and volume which render the yarn particularly suitable for the production of unusual and heretofore unobtainable fabric textures and appearances. Other objects will appear hereinafter.

The method and apparatus which may be used for producing this novel yarn form the subject matter of my companion application Ser. No. 544,886 filed Nov. 4, 1955. However, certain reference to suitable method and apparatus for producing the yarn of the present invention will be set forth below.

My novel highly volumized yarn may be obtained by feeding a number of continuous yarn filament bundles into a high velocity air jet at different speeds of feed. For convenience of description certain of this filament bundle feed will be referred to as excess yarn and others will be termed core yarn. My air jet is characterized by its minimum of air turbulence and its high efficiency of conversion of static into velocity pressure. The excess yarn treated in the jet is removed from the jet at a substantially slower rate than it is fed in, say, for example, one-half as fast as it is fed in. At the same time the excess yarn is being supplied, another continuous filament yarn from another source comprising a bundle of filaments which I term the core yarn is fed simultaneously to the jet. This core yarn is of a total denier not substantially greater and usually substantially smaller in total denier than the excess yarn. The rate of feed of the core yarn is only slightly faster than the rate at which the excess yarn is removed.

By this procedure just generally outlined, the passage of the core yarn and excess yarn through the jet blooms out and intermingles the individual filaments of both the core and excess yarn with each other and with the air stream. As the intermingled fibers of both yarns exit from the jet and are removed from the air stream, preferably somewhat abruptly and at an angle to the direction of flow of the air stream, certain novel effects occur. That is, the excess yarn filaments tend to continue in the line of the air stream but are restrained by their intermingled state with the core yarn. As a result, there is formed a multitude of filament and yarn loops. The excess yarn filaments as disorganized groups tend to weave back and forth in the structure of the core yarn filaments.

Inasmuch as the rate of feed of the core yarn is controlled, there is a slight contraction of the core yarn which allows the core yarn filaments to be opened up or bloomed out. This facilitates the penetration of the excess yarn filaments in and out and around the core yarn filaments to achieve an intimate interweaving of the individual filaments of both yarns and to form arch-shaped loops. Since there is an excess of filament length in the excess yarn, the filaments loop and stand out in the core yarn in a novel and attractive manner. Also, because of this interweaving, the need of twist to hold the filament loops of the excess yarn locked in place is eliminated, but as will be pointed out hereinafter in certain of the examples, I prefer to apply a certain amount of aftertwist.

For better understanding of my invention, reference is made to the attached drawing forming a part of the present disclosure. In the attached drawing,

FIG. 1 is a diagrammatic longitudinal cross-section illustration which for clarity shows only one filament of excess yarn. The type of loop shape and the interweaving in the core will be more easily observable from this figure.

FIG. 2 is a cross-sectional end view showing in further detail the internal structure of the yarn illustrated in FIG. 1.

FIG. 3 is a graphic illustration of a heavy denier yarn product of the present invention having the preferred structure with numerous arch-type loops through the core yarn.

FIG. 4 is a graphic illustration of another effect which may be obtained in yarn of the present invention whereby in addition to the arch-type loop certain smaller loops are obtained on the filaments.

FIGS. 5, 6, and 7 are graphic illustrations similar to FIGS. 3 and 4 but wherein various ratios of excess to core such as 2.5-4/1 are shown.

Referring now to FIG. 1 wherein a simplified structure has been illustrated for better explaining this invention, one filament of excess yarn is shown at 1, and several filaments of core yarn at 2. It will be noted that the excess yarn is interwoven in the form of arch-type loops through the core yarn.

FIG. 2, which is an end view of the yarn, shows the random arrangement of the arch-type loop fonmatio n. As already pointed out, FIGS. 1 and 2 with the single filament of excess yarn have been presented for assisting in providing a more convenient understanding of the present invention. In commercial operations, however, there would be used in most instances a plurality of filaments for both the core and the excess yarns and the two yarns fed together at various different speeds and ratios.

FIGS. 3-7 with the legends set forth with respect to these figures diagrammatically illustrate some of the different yarns which would be obtained using a greater number of filaments and various ratios and the like.

It will be noted that the novel yarn product of the present invention results in that the excess yarn feed is at a considerably higher rate than the core yarn feed. The correlation of speeds of the yarn feeds is an important feature in obtaining the product of the present invention. That is, by controlling the core yarn feed in a. certain manner, it is caused to slightly open up thereby permitting the excess yarn to penetrate in and out of the core and achieve interweaving. By the overall control of speed of yarn feed and other correlations which will be apparent from the description in the specific examples which follow, it is possible to obtain a Volumized yarn of appreciably greater total denier, say 100 to 500% greater than the starting yarns making up my novel Volumized yarn.

As pointed out above, twist is not required in my yarn of the present invention to lock the arch-type loops in place, since they are already locked in place by the interweaving of the excess yarn with the core yarn. Hence, the yarn may be packaged on a zero twist package type winder. However, I prefer to apply a certain amount of aftertwist to my yarn. Also, in some instances rather than starting with substantially zero twist yarn I may employ a pretwisted yarn.

A still further understanding of my invention will be had by a consideration of the following examples which are set forth for illustrating various embodiments.

Example I In accordance with this example yarn from two separate sources was fed into an air jet. For convenience of consideration the process conditions followed are tabulated below:

Excess yarn150 denier, 38 filaments, 3 t.p.i., d-ull white acetate.

Core yarn-150 denier, 38 filaments, 3 t.p.i., bright black acetate.

Excess yarn speed- 100 y.p.m.

Core yarn speed53 y.p.m.

Air pressure7 /2 p.s.i., gauge Output roll speed50 y.p.m.

Volumized yarn denier-440 measured, 460 theoretical Volumized yarn twist-0.00 t.p.i. in the ply.

The finished Volumized produced was compared and tested with other products:

4 Output roll speed-40 y.p.m. Volumized yarn denier-2200 measured, 2250 theoretical Volumized yarn twist--0.8 t.p.i.

Example III In accordance with this example 1200 denier core yarn was used and a 2850 denier excess yarn. Processing conditions were as follows:

Example I V In accordance with this example 1200/300/0 denier core yarn was used and a 2100/ 525/ 0 denier excess yarn. Processing conditions were as follows:

Excess yarn speed-52 y.p.m. Core yarn speedl3.7 y.p.m. Air pressure25 p.s.i.

Output roll speed12.5 y.p.m. Volumized yarn twist0. 0 t.p.i.

This 3300 denier input was Volumized 300% to give a 10,000 denier finished product.

Example V In accordance with this example 300/ 14/STZ denier core yarn was used and a 150/ 7/ STZ denier excess yarn. Processing conditions were as follows:

Excess yarn speedy.p.m. Core yarn speed13.7 y.p.m. Air pressure-15 p.s.i.

Output roll speed12.5 y.p.m. Volumized yarn twistl.7 t.p.i.

This 450 denier input was Volumized 100% to yield a 900 denier finished product.

Example VI In accordance with this example 200/ 100 STZ core yarn and 49/ STZ excess yarn of cellulose acetate were used. Processing conditions were as follows:

Excess yarn speed15 3 y.p.m. Core yarn speed-75.3 y.p.m.

S ecitic Percent Bulk Yarn Type olume Solid Cu. ins/lb. Acetate Volumized Yarn 136 650 Normal Bulk Yarn. 78 318 Spun Staple Yarn 56 266 Acetate Filament Yarn Regular Cross-Scct1on As may be noted from the above comparison the yarn of this example has several meritorious features. However, as will be discussed hereinafter in connection with certain of the other examples, I prefer my species of yarn wherein the loops are substantially all arch-type, free of crunodal loop formation.

Example 11 In this example different denier yarn was used and other conditions varied. For convenience of reference the data respecting this example is tabulated as follows:

Air pressure8 p.s.i.

. Output roll speed-73 y.p.m.

Twist in Volumized yarnl.7 t.p.i. Z

The resultant product had been Volumized 30% to a final denier of 360, and had the following characteristics:

Yarn strength.77 G/ D Yarn stretch-19.7% Specific volume8l cu. in./ lb.

Example VII In accordance with this example 160/ IOO/STZ polyester type core yarn and /52/STZ cellulose acetate excess yarn were used. Processing conditions were as follows:

Excess yarn feed43 y.p.m. Core yam feed-26.5 y.p.m. Air pressure-8 p.s.i., gage Output roll speed-25 y.p.m. Twist in ply-2.20 t.p.i. Z

The resultant product had been volumized 30% to a final denier of 410, and had the following characteristics:

Yarn strength-1.3 G/D Yarn stretch-28.4% Specific volume-81 While the yarn of the above two examples has certain merit it will be observed that the volumizing was only about 30%. Hence, I prefer the yarn of certain of the other examples where the yarn is volumized 100% and higher.

Example VIII In accordance with this example a 70 denier 34 filament /2 turn per inch Z twist nylon core yarn was used and excess yarn of 150 denier, 30 filament, 1 turn per inch Z twist solution-dyed acetate excess yarn.

In making the yarn of this example a snubbing bar tension was used and so adjusted that there was zero or substantially no tension in either the excess or core yarn between the jet and the snubbing bar. In the following table further examples are given wherein the speed and feed ratios, tensions and apparatus were the same but the composition of the core and excess yarns were varied.

acetate bright excess yarn were used. The ratios of feed and removal of the yarn from the jet were the same as in Example VIII.

Excess yarn feed speedSS y.p.m.

Core yarn feed speed25 y.p.m.

Air pressure-12 p.s.i. gage Output yarn speed24 y.p.m.

Volumized yarn twist4.7 t.p.i.

Final denier-800 Percent volumized or increase in denier-116% Ninety ends of this yarn were combined without twist and sprayed with triacetin plasticizer in the amount of 20% by weight. The bundle of yarn ends were then processed into a cigarette filter tip using hand operated cigarette rolling methods and equipment. The finished 25 mm. circumference filter tips were then evaluated for pressure drop and percent tar removal with the following results. The pressure drop was 8.3 inches of water per 90 mm. long rod, and the percent tar removal was 32%. By comparison a conventional presently commercial type filter tip made from 54,000 denier 2 D/F filter tow had a pressure drop of 8.6 inches of water and a removal of 24% of the tars. The remarkable improvement in filtration efiiciency of the volumized yarn filter tip may be attributed to the fact that a very high percentage of the fibers of the excess yarn were oriented perpendicular to the smoke stream, thus increasing the impingement of smoke particles and the opportunity for trapping said particles.

Two additional runs were conducted under equal conditions except that in one case 2 ends of 300/ 150/ 1Z excess yarn and an air pressure of 17 p.s.i. gage were used, and in the other case 3 ends of the same excess yarn and an air pressure of 20 p.s.i. gage were used instead of the one end of the previous example. In these Percent Elon. Elon. Samples Excess Yarn Cellulose Acetate Denier Increase G/D Dry, G/D Wet, Specific in Denier or Dry Percent Wet Percent Volume Volumized (1) Nylon Core 70/34/%Z (A) 150/38/LZ 420 90 1. 03 27 95 28 129. 1 (B) 2 Ends l/38/L 760 105 58 32 52 22 124. 1 (C) 300/75/LZ 800 116 53 25 49 23 117.6 (2) Cellulose Acetate Core, 150/38/1Z (A) 00/75/LZ 830 85 24 24 15 28 119.1 (B) 2 Ends 150/38/LZ 830 85 .23 30 14 31 119. 5 (C) 0/38/LZ 500 67 38 26 25 33 111 (3) Cellulose Acetate Core, 300/75/1Z (A) 300/75/LZ 1, 010 83 40 32 25 36 107. 4 (B) 2 Ends 150/38/L 990 65 40 29 23 32 109. 0 (C) 2 Ends 300/75/LZ 1,725 92 23 31 14 33 102. 3

It will be noted in these examples which represent my preferred product that in no case was the percent increase in denier or the percent volumized less than 65%. Moreover, in every case the specific volume in cubic inches per pound was over 100; whereas prior art lofting with comparable denier per filament supply yarns produces only about 80 cubic inches per pound specific volume.

Example IX In accordance with this example a 100/50/ /2Z bright nylon yarn and a 150/38/1Z cellulose acetate solution dyed green yarn were used as a core yarn by combining them at the input core yarn feed roll. The excess yarn was composed of 3 ends of 150/ 38/ 12 cellulose acetate solution dyed green yarn, combined at the excess yarn input feed roll. The ratio of the speed of the excess yarn to the core yarn was 12.3 to l. The speed of the core yarn was 5 y.p.m. The yarn was wound up without adding any twist. The final product had a denier of 6115 or an increase of 760% in denier or percent volumized. This yarn product may be used as a decorative yarn such as used for Christmas tree garlands, etc.

Example X In accordance with this example, a 70/34/ /2Z bright nylon core yarn and one end of 300/ 150/ 1Z cellulose cases where filters were made and tested, the following results were obtained.

Both of these filters were better in tar removal than a conventional rod of about equal pressure drop but were not quite as elficient as the filter tips made from the ends of 800 denier. This may be because more opportunity existed for channeling between the yarn ends as the yarn denier increased and the number of plies in the filter tip decreased.

It will also be noted that this particular form of volumized yarn is useful for rough novelty textured fabrics.

In the above examples the y.p.m. reference means yards per minute of speed of passage of the yarn through the volumizing device. p.s.i. means pounds of pressure per square inch, and t.p.i. means twist per inch. STZ means spun twist in Z direction.

In the above examples the yarn was treated with a treating agent. The particular treating agent used was comprised of mineral oil from about 40-85%, petroleum sulfonate from 540% and small amounts of one or more of the ingredients from the group consisting of. glycol ethers and fatty acids and amine alcohols. This treating agent, which is characterized by high scroop and static properties, functions to aid in producing a finished yarn wherein the first yarn is interwoven into the second yarn in a manner that the interwoven filaments will not readily pull out of the core.

Although in the above examples I have described a number of products comprising cellulose ester yarn, and prefer such products, it is possible to use yarn of other chemical composition. That is, in the broader aspect of my invention my new yarn may be made up of multifilament yarns of viscose, polyamides (nylon), acrylonitrile yarns, polyester yarns and the like. It is possible to employ a polyamide or polyester type core yarn and use excess yarn of acetate or viscose in order to provide a volumized yarn which has higher tensile strength.

In connection with FIGS. 4 and 7, it will be noted that the excess yarn tends to interweave in the core yarn more as a'single yarn rather than as a group of disorganized filaments. Also, attention is called to the fact that this condition is brought about by using a twisted excess yarn, the twist acting to hold the filaments of the excess yarn together to an extent proportional to the degree of twist. In this situation where predominantly yarn loops are formed by the excess yarn, there are often a large number of small individual filament loops present protruding from the excess yarn.

It will also be noted that the volumized product of the present invention differs considerably from prior art type of yarn such as boucle. That is, in boucle yarn the excess yarn surrounds the core yarn as a bundle of filaments. Also, boucle yarn usually requires a third binder yarn twisted about it to hold the surrounding yarn in place. That is, in contrast to such boucle yarn it will be noted that in the new yarn of the present invention the excess yarn is interwoven into the core yarn as individual filaments or disorganized groups of filaments thereby not necessitating twist or a third yarn to hold the excess yarn in place. Likewise, the yarn of the present invention substantially distinguishes from a type of yarn known as dilferential shrinkage yarn in that such yarn also does not have interweaving of filaments and requires twist to 'hold the flufiiness in place under tension.

The new yarn produced by the present invention, in addition to its greatly increased bulk, exhibits adequate strength, particularly if certain types of yarn are used as the core, and many novelty appearance effects may be produced.

I claim:

1. As a new product, substantially untwisted, bulked yarn comprising a separate core yarn of cellulose ester and separate excess yarn of cellulose ester interwoven back and forth in said core yarn, said excess yarn at a number of points extending through said core yarn and forming a multitude of small loops on the outside of said core yarn, said finished yarn having an increase of denier of greater than 50% over the combined denier of the untreated core and excess yarn.

2. As a new product, substantially untwisted, volumized yarn comprising a separate core yarn and separate excess yarn interwoven back and forth in said core yarn, said excess yarn at a number of points extending through said core yarn and forming a multitude of small loops on the outside of said core yarn, said finished yarn having an increase of denier of greater than 100% over the combined denier of the untreated core and excess yarn.

3. As a new product, volumized yarn comprising a multifilament core yarn, and multifilament excess yarn interwoven back and forth in said core yarn, said excess yarn at a number of points extending through said core yarn and forming a multitude of arch-shaped loops outside of the core yarn, said volumized yarn having an increase in denier of greater than 65% over the sum of the deniers of the excess yarn and the core yarn, and said volumized yarn being further characterized in that it has a specific volume in en. in./lb. of over 100.

4. A product in accordance with claim 3 wherein the volumized yarn contains after-twist up to 10 turns.

5. A product in accordance with claim 3 wherein the volumized yarn is of a total denier of at least 10,000.

6. A product in accordance with claim 3 wherein the denier of the excess yarn is at least twice the denier of the core yarn.

7. A product in accordance with claim 3 wherein the core yarn is from the group consisting of polyester and polyamide yarns and the excess yarn is a cellulose ester yarn.

8. A product in accordance with claim 3 wherein the core yarn is of 300 denier and the excess yarn is of 1,100 denier.

9. A product in accordance with claim 3 wherein the volumized yarn contains at least three ends of excess yarn.

10. A product in accordance with claim 3 wherein at least one of the multifilament yarns is solution dyed.

11. A product in accordance with claim 3 wherein the core yarn has less than 5 turns twist and the excess yarn is substantially untwisted.

12. A product in accordance with claim 3 wherein the core yarn is substantially untwisted and the excess yarn contains less than 10 turns of twist.

13. A product in accordance with claim 3 wherein the core yarn and a separate excess yarn each contain less than 5 turns of twist.

14. As a new product, substantially untwisted, v01- umized yarn containing a separate core yarn and a separate excess yarn having at least one turn of twist, said excess yarn interwoven back and forth in said core yarn, said excess yarn at a number of points extending through said core yarn and forming a multitude of yarn loops on the outside of said core yarn, said excess yarn loops being further characterized by the presence of individually looped filaments, the said finished yarn having an increase of denier of greater than 50% over the combined denier of the untreated core and excess yarn.

15. A bulky yarn comprising a separate core yarn and separate excess yarn interwoven back and forth in said core yarn, said excess yarn at a number of random points extending through said core yarn and forming a multitude of elongated loops on the outside of said core yarn, said finished yarn having an increase of denier of greater than 50% over the combined denier of the untreated core and excess yarn.

16. A product in accordance with claim 15 wherein the bulky yarn contains after-twist of up to 10 turns.

References Cited UNITED STATES PATENTS 2,864,230 12/1'958 Moore 57-157 2,869,967 1/1959 Breen 57--34 2,874,444 2/ 1959 Griset S7-34 2,504,523 4/1950 Harris 57-140 2,852,906 9/1958 Breen 5734 2,535,376 12/ 1950 Thompson 57l43 MERVIN STEIN, Primary Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,410,076 November 12, 1968 Richard P. Dyer It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, lines 36 and 39, "3 t.p.i.", each occurrence, should read .3 t.p.i. Column 4, line 14, "37%" should read 370% Column 9, line 1, beginning with "the complex" cancel all to and including "Melvin D. Rein, Primary Examiner." in line 75, column 12.

Signed and sealed this 5th day of May 1970.

(SEAL) Attest:

Edward M. Fletcher, Jr. E.

Attesting Officer Commissioner of Patents 

2. AS A NEW PRODUCT, SUBSTANTIALLY UNTWISTED, VOLUMIZED YARN COMPRISING A SEPARATE CORE YARN AND SEPARATE EXCESS YARN INTERWOVEN BACK AND FORTH IN SAID CORE YARN, SAID EXCESS YARN AT A NUMBER OF POINTS EXTENDING THROUGH SAID CORE YARN AND FORMING A MULTITUDE OF SMALL LOOPS ON THE OUTSIDE OF SAID CORE YARN, SAID FINISHED YARN HAVING AN INCREASE OF DENIER OF GREATER THAN 100% OVER THE COMBINED DENIER OF THE UNTREATED CORE AND EXCESS YARN. 